Automatic control switch



June 17 1924. 1,498,347

w. w. BUCHER AUTOMATIC CONTROL- swn'cn Filed March 20, 1919 4Sheets-Sheet 1 30%Iz5vllfayrzei 6018451114, W, M qeahr 1/ 77.5. dam/June 17 1924 W. W. BUCHER AUTOMATI C CONTROL SWITCH Filed March 20. 19194 Shegts-Sheet 2 June 17 1924. 1,498,347

' w. w. BUCHER I AUTOMATIC CONTROL SWITCH Fil ed March 20, 1919 4Sheets-Sheet 5 (war 1 Fax/Han:

Patented June 17, 1924.

UNITED STATES PATENT OFFICE.

WILLIAM W. BUCHER, OF CHICAGO, ILLINOIS, ASSIGNOR, BY MESNE ASSIGNMENTS,TO KOHLER COMPANY, OF KOHLER, WISCONSIN, A CORPORATION OF WISCONSIN.

AUTOMATIC CONTROL SWITCH.

Application filed March 20, 1919. Serial No. 283,913.

T 0 all whom it may concern;

Be it known that WILLIAM BUCHER,

citizen of the United States, residing at Chicago, in the county of Cookand State of Illinois, has invented certain new and useful Improvementsin Automatic Control Switches, of which the following is aspecification. My invention relates to improvements in automatic controlswitches and it more especially consists of the features pointed out inthe annexed claims.

Among the purposes of this invention the following are mentioned: (1) toprovide a self contained switch unit adapted to control the starting,running and stopping of isolated electric generating plants which aredriven by internal combustion engines; (2) to provide a switch havingall the interrelated parts assembled and operative on a single base; toprovide a sensitive starting and stopping control, a running control, astarting magnet and a running. magnet all cooperating with each otherautomatically through the initial turning on of a single lamp and thefinal turning off of the last lamp; (4) to make special provision forcon trolling the use of a low voltage current temporarily on normal orhigh voltage service mains so as to employ a high voltage generator asa. motor to start the engine, by using a low voltage current in thegenerator armature and shunt windings; to recurrently, with greatuniformity, after the generator has been operated at low voltage as astart- 7 ing motor, insure that it will deliver a high voltage currentto the service mains after the engine has come to speed. instead of thecurrent at the low voltage of the battery; (6) to provide a combinedswitch that shall direct the operation of a generating plant regardlessof the polarity of the starting current, thus simplifying theinstallation and the running of plants of this type without theemployment of expert electricians: (7) and also to concentrate 'all thecontrol functions in a single unit, usually supported on the generator.without the use of separate switches and a switch board.

Attention is directed to a copending application on a system in whichthis invention is employed. Serial No. 283,910. filed March 20th, 1919.

With these and other ends in view I illustrate in the accompanyingdrawings such instances of adaptation as will disclose the broadunderlying principles without limiting myself to the specific detailsshown.

Fig. 1 is a front elevation of a complete switch unit. (This would be aside eleva tion if shown on the generator to conform with the feet ofthe under base.)

Fig. 2 is a side elevation partly in section of' Fig. 1.

Fig. 3 is a detached elevation of a control plate serving to makecontact with various circuits.

Fig. 4 is a diagrammatic plan view of-the related circuits in connectionwith the component parts of a complete plant, showing the coils ormagnets and contacts in elevation.

Fig. 5 is a diagrammatic view of'Figs. 1 and with the related workingparts connected.

Fig. 6 is a plan of a core aligning plate. Isolated generating plants ofthe low voltage starting and high voltage generating type, employing thesame machine for generating and starting are in an entirely differentpractical class from those known to the prior art.

In the use of a separate starting unit attached to a dynamo similarpractical difliculties are not encountered as when the same machine isused at two radically different voltages, at periods immediatelyfollowing each otherone voltage dependent on the machine itself and theother on an external source. The use of the terms high, standard ornormal voltage for the purpose of this description approximates 110115volts, and the term low voltage approximates 24 volts or less within apractical working range.

In practically carrying out my invention I may use the specific detailsinstanced in the accompanying drawings or any alterations thereof thatthe exigencies of actual practice may ,demand without departing from thespirit of my invention.

The switch parts are mounted on a base 3. These comprise an insulatingplate 1, a magnet support 8, having feet 10, for the starting magnet 47and the running magnet 43; also another support 2 for the startingcontrol magnet 63 and the running control magnet 28. These are woundover each other so as to be handleable as a unit. Along the edges of thebase 3' insulating strips 3, 4, and 5 are placed. Strip v3 has termlnalsfor the generator 2 and the magneto 21; strip 4 accommodates the servicemain terminals 59 and 60, also the ends of wires 66 and 73 of thecharging resistance 25. The other strip 5 has plug terminals 7 for thestorage battery 26. The fourth edge has terminals 98 in insulatingbushings for the wires 75 and 76 of the governor control 27, actuated bythe governor 20, not shown but indicated by name. The terminals onstrips 3 and 4 are held by nuts 97 only shown on Fig. 1.

Before referring to the component parts of the switch, each of thedevices, etc., that are served by the switch will be described,commencing with the battery 26. This is a self-contained battery ofapproximately 12 cells, or less, known as a low voltage startingbattery. It is connected to plu s 7 by the usual well known socketpull-o terminals (not shown). It is immaterial so far as the startingfeatures, etc, are concerned,

whether theterminals .are placed in a definite relation to the plugs, asto polarity, because in practice it 1s found that the generator willaccommodate itself to either start- 1 ing polarity automatically withoutdestroying the proper current direction for charging the battery 26'through resistance 25. This resistance may be substituted by any wellknown form of automatic charging control as desired.

The generator 2 is of the compound Wound type, having a shunt field 55and a series field 53. If desired, for any reason, to additionallycompensate the dynamo a winding 54 may be used. It is to be understood,however that the main features ofthe switch unit are not limited to thespecific embodiment of the dynamo construction.

' The terminal 52 is connected to starting magnet contact 46, over wire68, and the terminal 56 is connected to the negative battery pole 7. At57 it is also connected to running magnet 43, and separately to thestarting magnet 47 over wire 74. Beyond the junction 57 it. continues asa service mam 60.

The series field 53 is connected by wire 67 from terminal 52' to therunning magnet 43. The wire 67 continues past the junction 58 to thecontact 40. In starting, all the w1res, 60, 68, and 67 are active, butunder running conditions the wire 68 is not used.

The magneto 21 has a primary coil 77 an a secondary coil 78 serving thespark plugs of the driving engine, not shown. A circuit over wire 71,grounded at 81, connects with the two sides of the primary coil 77 andthe under contact 36 of the magnet 2863. This circuit is also groundedbeyond the contact 37, at 82.

The engine governor 20, in any well known manner, not shown, actuatesthe arm 14 fulcrumed at 15. The arm 14 has a short extension 17 which iscontrolled by a dash pot 16 to prevent hunting. Another extension 18carries a counter weight 19 to balance the governor lever system. 14 hastwo links pivoted thereto. The link 12 isattached to the engine throttleand the link 13 to the carbureter choker, so as to maintain a uniformvoltage by the dynamo, under varying loads. As these features are madethe subject of a separate application they are not specifically shown orfurther described. When the arm 14 is at rest contacts 27 remain closed.Its wires and 76 lead to the following switch parts, 75 to contact 34 ofthe control magnet 28-63. The wire 76 leads to contact 33 of the runningmagnet 43.

Service mains 59 and 60 supply lamps, 50, controlled by switches 49, orany other current consuming accessories operable at ordinary 110-115volts, supplied by the generator 2, though this same generator with itshigh voltage windings, the service mains and accessory 50 aretemporarily subjected to a low voltage battery current on starting.

The resistance 25 through which the battery is constantly beingrecharged, is connected by wire 73 to contact 42, Figs. 1 and 2.- (Sincethe contacts 45, 42, 41, and 31 occurdirectly above each other, to avoidconfusion in the plan view, Fig. 5, they arethe battery 26, and also tocontacts 31 and 45.

The arm the resistance 25 to the positive pole 7 of p The iron support8, as stated, holds magnets 47 and 43, the former on cross bar 9' andthe latter on cross bar 99 fastened to the sides 8at100. Each of themagnets has an iron yoke, respectively 22 and 23 secured to the crossbars 9 and 99. The magnet spools are placed within the yokes on shortcores 48 and 24. A sliding core 51 with its slot 72 moves in magnet 47and a similar core 64 having slot 65 slides 'in magnet 43. The cores 24and 48 may be made of any desired length according to the density offlux required in the air gap. This construction practically makes asolenoid of each magnet, cores 51 and 64 constituting the plungers orarmatures. v

The province of movable cores 51 and 64 is to respectively control theposition of the flexible contact bars 44, 88 and 39 so as to connect theproper circuits as may he demanded. These bars are formed of laminatedcopper so as to be elastic. The bar 44 has a single leaf extension 79projecting beyond each end of the bar, to which arcing pieces 80 ofhelmet bronze are attached. Thesesave the contactsproper fromdeterioratlon. .The bar 39 has a single arc pre venting member 83 whichcoacts with contacts 31 and 42. The bar 44 serves contacts 45 and 46,and bar 39 serves contacts 40 and 42, while bar 88 serves underneath contacts 31 and 33. The bar 44 is insulated from the core 51 by bushings 86and is held by nut 87. The combined bars 39 and 88 are similarlyinsulated from the core 64 by bushings 84 and are held in place by nut85. Slots 72 and 65 of cores 51 and 64 coact with projections 91 ofplates 90 (Fig. 6) to prevent the cores turning on their axis to destroythe working relation of the bars to their respective contacts.

All the contacts 45, 46; 40, 42, 41; and 31, 33 are substantialduplicates of each other. They have an enlarged rectangular head withbeveled faces 89, shoulders 101 and threaded stems on which nuts to holdthem and their wire connections are placed. Contacts and 46 areinsulated from cross bar 9 by bushings 92, contacts 41 and 42 from' bar99 by bushings 94, and contact 40 from the same bar by bushings 93. Apig tail connection 32 is made at 96 to the bar 39. This is connected bywire 62 to the fine wire starting control coil 63. Contacts 41 and 42are narrower than the others because they are placed side by side on thecross bar 99.

-Wire 73 connects contact 42 to the resistance 25; wire 69 connectscontact 41 to the coarse wire coil 28; wire 61 connects contact 31 tothe battery 26; wire 68 connects contact 46 to terminal 52' of thedynamo 2; wire 67 connects contact 40 to the series field 53 of thedynamo; wire 76 connects contact 33 with the governor control 27. Themagnet 47 is connected by wire 7 O to contact35 and wire 74 connectswith service main 60 at 57.

The starting and running control magnets 28 and 63 are also made thesubject of a separate application, but their cooperative relation, inconstruction, etc., to form a i switch unit is substantially as follows.A

core 6 is placed inside the coils. It has a central hole 37' in whicharmature stem 14 slides. This stem carries a diaphragm armature 11 ofextremely light weight to make the responsiveness of the magnet verysensitive. The stem also carries a contact disk 38 insulated by bushings95. Above the disk 38 are two contacts 34 and 35, Figs. 2

' and 5, the former connecting governor control 27 by wire 75 and thelatter connecting starting magnet 47 by wire 70. Beneath the late 38contacts 36 and 37 are placed. The 'ormer leads over wire 71 to themagneto 21 and the latter is grounded at 82 under the support 2. Themagnet 24-63 has an iron casing 30 which holds the parts assembled onsupport 2.

The operation of the switch is as follows, all the parts being at restas shown in Figs. 1,, 2, and 4, with the magneto grounded. A

of its windings being only rating,

52, and along wire 65 to the battery. This current is of very smallamperage and must be utilized to the utmost to continuously andeffectively control the starting function whenever required. It attractsdiaphragm 11, and the first part of this movement disconnects contacts36 and 37, to make the magneto 21 operative. The final movement bringsthe plate 38 against contacts 34 and 35, completing the first stage ofthe starting operation.

The last movement of plate 38 is the initial step of the second startingstage. It connects contacts 34 and 35, closing the circuit of thestarting magnet 47, over line 70 and line 75. This circuit, startingfrom the battery, leads past points 29 and 30, line 61 to under contact31, bar 3988, under contact 33, line 76, closed governor control 27,line 75, contacts 34 and 35 and plate 38, line 70, magnet 47 line 74 tojunction 57, line to 52 and line to the negative side of the battery 26.This current energizes magnet 47 which through the attraction of bar 44-engages contacts 45 and 46.

The operation of magnet 47 forms the third stage of a startingoperation. It admits a heavy low voltage current from the.

battery,- past points 29 and 30 to contact 45, bar 44, contact 46, line68 to terminal 52' of the high voltage generator 2, flowing only throughits armature and the shunt field 55 to terminal 56, to junction 52 online 60, and then over line 65 back to the battery. This circuitutilizes the generator 2 as a motor to start the engine.

The fourth stage of the starting operation immediately follows thepreceding one. It might also be called the first stage of actualrunning. It consists of a positive disconnection of the battery currentfrom magnet 47 by the engine governor 20, at 27, as the engine comes upto a predetermined speed. Instead of this disconnection the circuitmight also be broken at 33, but the low battery voltage on which such analternative breaking depends would not be sufiicient to energize therunning magnet 43 On account 7 adapted to the high .voltage current fromthe generator. In view of this, if the circuit was not broken by thegovernor at contact 27 the generator could not build up its voltage toits normal but its voltage would remain approximately at that of thebattery. This would defeat the basic purpose of the system, whichconsists in supplying standard current consuming devices, etc., at theirnormal battery to furnish current at 110-l15 volts in contrast to but 12cells with my system.

The last stage of the full running phase of operation-is reached whenthe governor 20 has opened the starting magnet circuit at 27 and theoncoming high voltage of the generator 2 has energized the runningmagnet 43 to hold bar 39 away from contacts 31 and 33 but againstcontacts 41, 40, and 42. The magnets 43 and 2863 remain in circuit solong as a demand exists on the service mains 59 and for current, thusretaining the bar 39 and plate 38 in a raised position, but the pig tail32 always remains connected to bar 3988.

The current delivered by the dynamo at the high voltage would possiblyinjure the coil 63, wound for a low voltage current, so, in order toguard against this the coil 63 may be cut out altogether by bar 39 or beplaced in parallel with the heavy current coil 28, in order to protectthe fine wire coil 63 from injury. It is necessary that the coil 28 bekept energized at all times, throughout the full running operation ofthe plant, so as to not ground the magneto by bar 38 dropping intoengagement with contacts 36 and 37. j V

The running relation of the circuits supplied by the dynamo is asfollows :Starting from 52 at the generator 2 the line is traced throughseries field 53 onto line 67 passing junction 58, to contact 40, bar 39to contact 42, over line 73, resistance 25, line 66 to junction 29, tothe positive side of the battery 26, then over line to point 52 and line60 back to the generator terminal 56. The shunt coil 55 may be a shortshunt as shown or a lon shunt including the series soil 53, ELSdQSlI'Bd.

The primary purpose of the generator 3 a is to serve the mains 59 and60. The course coil 28, line 59, lamps50, etc., switch 49 and line 60,passing points 57 and 52, back to the generator terminal 56 of dynamo2..

This main current keeps themagneto operfative through the activity ofmagnet 28 which prevents the grounding circuit 71 beingput intoacti'ori'by reason of bar 38 remaining in its raised-position.

- 'The stopping procedure 'slmply consists I of one operation, that is,tdrning off the last lamp 50, or other accessory, which breaks theservice lines and stops theflow of current. through magnet 28 63.7In-the abcoil of the control switch.

sence of current the magnet is demagnetized, causing the bar 38 to droponto the contacts 36 and 37, grounding the'magneto 21 between it and theprimary coil 77. All the parts of the switch return to their idleposition ready to be used for a subsequent start when needed.

It will be seen from the description how interdependent the severalparts are and how essential it is for the successful opera- 75 tion ofplants of this type that all of these vital elements arernade automatici-n operation and in addition form the component parts of a single unit.

What Iclaim is 1. In combination with a gas-engine driven generator, itsservice mains and a storage battery, a control switch having a magnetcoil in series with the battery and the service mains when the generatoris idle, engine-disabling means controlled by the control switch, amotor-starting switch having a magnet coil in a circuit also controlledby the control switch, a circuit including the battery and generatorcontrolled by the motor-starting switch, a main switch operseed from thegenerator for connecting the generator to the service mains when thegenerator attains suflicient speed, and a second magnet coil for thecontrol switch in series with the service mains when the generator is inoperation.

'2. In combination with a gas-engine driven generator, its service mainsand a storagebattery, a control switch having a 109 magnetcoil in serieswith the battery and the service mains, engine-disabling. meanscontrolled by-the control switch, amotorstarting switch having a magnetcoil in a circuit also controlled by the control switch, a circuitincluding the battery and generator controlled by the motor-startingswitch, and a main switch operated from the generator forconnecting thegenerator to the service mains when the generator at- 110 tainssufiicient speed.

3. In combination with a gas-engme driven generator, its service mainsand a storage battery; a control switch having a magnet coil in'serieswith the battery andllfi the service mains when the generator is idle,engine-disabling means controlled by the ontrol switch, a motor-startingswitch havi g a magnet coil in a circuit also controlled bythecontrolswitch, a circuit including the battery and generator controlled by themotor-starting switch, a main switch operated from the generator forconnecting the generator to the service mains when the generator attainssufiicient speed, a second mag- 1 net coil for the control switch inseries with the service mains, and means operating with Y the mainswitch for substituting the second magnet coil for the first mentionedmagnet.

by the main switch.

4. In combination with a gas-engine driven generator, its service mainsand a storage attery, a control switch having a magnet coil in serieswith the battery and the service mains, engine-disabling meanscontrolled by the control switch, a motor starting switch having a.magnet coil in a circuit also controlled by the control switch, acircuit including the battery and generator controlled by themotor-starting switch, a main switch operated from the generator forconnecting the generator to the service mains when the generator attainssuflicient. speed, a second magnet coil for the control switch, andmeans operating with the main switch for connecting the second magnetcoil in parallel with the first mentioned magnet coil of the controlswitch.

5. In combination with a gas-engine operated generator, a storagebattery and service mains, a control switch having a fine winding incircuit with the battery and the mains in order to be energized by aservice demand, an engine ignition means in a circuit controlled by thecontrol switch, a starting switch having a winding ina circuit alsocontrolled by the control switch, a motor circuit including the batteryand the generator as a motor and controlled by the mo tor-startingswitch, and a main switch having a windin connected in circuit with thegenerator an energized when the generator is driven by the engine, saidcontrol switch having a coarse wire winding in circuit with the mainsand the generator and controlled 6. In combination with a gas-engineoperated compound wound generator and storage battery and service mains,a control switch having a fine winding in circuit with the battery andthe mains in order to be energized by a service demand, an engineignition means in a circuit controlled by the control switch, a startingswitch having a winding in a circuit also controlled by the controlswitch, a starting circuit including the battery and the armature andshunt field winding of the generator for operating the generator as amotor and controlled by the motorstarting switch, and a main switchhaving a windinglconnected in circuit with the armature of t e generatorand energized when the generator is driven by the engine, said controlswitch having a coarse wire winding in circuit with the mains and thearmature and series field winding of the generator and controlledby themain switch.

7. In automatic control switches for'gasengine operated generatorplants, a control switch serving both as a starting and running control,a battery supplying initial current to the control switch magnet, astarting switch having a magnet coil in a circuit controlled by thecontrol switch, an electric-motor-starting-circuit controlled by thestarting switch, an engine ignition circuit made operative andinoperative by the control switch,a main switch, a generator connectedto the magnet thereof, service mains supplied by the generator, andmeans controlled by the main switch to maintain the control switch inoperated position so long as a demand continues on the service mains.

8. In combination with a gas-engine operated generator and its mains, acontrol switch serving both as a starting and running control, a batterysupplying initial current to the control switch magnet through themains, a starting switch having a magnet coil in a circuit controlled bythe control switch, an electric motor starting circuit controlled by thestarting switch, an engine ignition circuit made operative andinoperative by the control switch, a main switch, the generator beingconnected to the magnet of the main switch and connected to the servicemains by means of the main switch, and means controlled by the mainswitch to maintain the control switch in operated position so long ascurrent is delivered to the service mains by the generator.

9. In combination with a gas-engine operated generator and its mains, acontrol switch serving both as a starting and running control, a batterysupplying initial current to the control switch magnet through themains, a starting switch having a magnet coil in a circuit controlled bythe control switch, an electric motor -starting circuit controlled bythe starting switch, an englne ignition circuit made operative and inoerative by the control switch, a main switc the generator beingconnected to the magnet thereof and connected to the service mainsthrough the main switch, means controlled by the main switch to maintainthe control switch in its bperated position so long as current isdelivered to:t e service mains by the generator, and means operated bythe main switch to cause the battery to be charged from the generator.

In testimony whereof I afiix my signatures WILLIAM W. BUCHER.

